Method and apparatus for cutting gears



July 2, 1935. B. E. sHLEslNGER METHOD AND APPARATUS FOR CUTTING GEARS :Snventor Patented July 2, 1935 eArsNT orties e 2,006,750- c A METHOD AND APPARATUS Foa CUTTING t A GsAas Y l Bernard-Edward Shlesinger, lronde'quoit, N. Y., assigner-'to Gleason Works, Rochester, N. Y., a

corporation of New York Application Mai-eh 1o, 1933, srialNo. 660,281, Y

l 1l Claims.

The present invention` relates to methods and apparatus for cutting longitudinally curved tooth gears and particularly to a method and apparatusfor cutting longitudinally curvedA toothv 45 tapered gears, such as spiral bevel and ihypoid gears, with a tool of the face-mill type. Y Longitudinally curved tooth gears can be cut with reciprocating tools or with face mills, For production work,y the face-millis the4 tool usually employed and the method of cutting is an intermittent indexingrprocess. The cutter has a plurality of equi-spaced, annularly arranged cutting blades. It is alternately fed intoY and withdrawn from engagement with the blank. During the periods ofv feed, a tooth-surface of a pair of tooth surfaces of the blank are completely cut and during the periods of withdrawal, the-blank is indexed. The cutting operation iscompleted when the blank has been indexedY through one revolution.A

AtV diierent times, efforts have been made to cut longitudinally curved tooth gears with face mills in a continuous indexingV process. A continuous indexing process oiTers theoretically sev eral advantages. Tool-wear and the heat generated by thefriction .of cuttingare distributed evenly over all the 4teeth of the blank, for all the teeth are being operated onsimultaneously, and theoretically better tooth-spacing should result.

. Moreover, the time lost through indexing and indexing withdrawals is eliminated. While .reciprocatingitools have. been employed successfully in al continuous indexingv process'where provision has beenmadeto compensate for the Y 1 variable motion ofthevtool under actuation of the crank, no satisfactory method has heretofore been devised .for cutting longitudinally curved tooth gears with a face-mill in a continuous indexing process. The difculty'has beento secure a satisfactory form of cutting tool. j In a continuous indexing process,ithe blank is rotating continuously and it rotates away'fro'm one side of a cutting blade and into the other side of that blade as the blade moves across the face ofv the blank. This causes the cutting clearance or angle between the sides of the blade and the tooth surfaces being cut therebyl to change continuously as the cutting blade moves across the face of the blank.v Hence, with any' g previously known continuous indexing process, a standard face mill cutter could not be employed. Various other forms of face-mill cutters which have been suggested, have not proved practical.V

Thus, cutters have been. made lwith blades whose rear ends have been oisetwith reference tostheir ing, distribution'of tool wear .and of the friccutting edges so as to secure the proper cutting clearance, cutters have .been made with blades similar to standard cutting blades but of higher pressure'a'ngle, etc. In the type Aof cutter rst mentioned, the blades must be adjusted radially 5 after sharpening and as yagainst the standard facemillfcutter in 'which'no adjustmentfof theA blades is required, this has 'constituted a decisive disadvantage. In .the second `type of` cutter mentioned, there is too much clearance on one 10A side of the blade and gears of standard pressure angle cannot be produced- Other objections apply toother types of continuous indexing cutters and so the continuous indexing process has never come into lcommercial use. Y

The primary Vpurpose of the present invention isft'o provide avgear cutting process which possesses all the advantages of the continuous indexing processY so far asaccuracy of tooth spactional heat of rcutting are concerned and in which a practical form of' face-mill can be employed. Theinventionis also applicable, however, to the cutting of gears with a reciprocating tool Where the toolris swung in a ,curved path to produce the lengthwisetooth shape. l A facefmill cuttingftool made for use in the present methodihas'blades of exactly thesame type as are used in the standard face mill gear cutter of the intermittent indexing process. The onlydierence is that the blades are arranged only part-wayaround the circumference of the cutterf If a single. series of blades are employed, thereis a relatively large space between the rst and lastb-lades of the series, while if the blades are arranged in more than one series, there is a much larger space between the last blade of each series and the first blade of the next series than there is between adjacent Vblades of a series.

'I'heinvention will beY described particularly in connection with the cutting of gears with a facemill. In this case, both the cutter and blank are rotated continuously in engagement and simultaneously va to and fro motion Vof translation is imparted between them. While a series of blades 45- form angle of clearance between the cutting blades and gear blank as the blades move across the face of the blank, while, during the return translatory movement, the continued rotation of the blank operates to index the blank so that when the first blade of the next series or the rst blade of the cutter rotates into position to cut, it will enter a new tooth space of the blank.

No new equipment is required to manufacture the blades of the face-mill cutter used inthe present invention. They are of standard form, and they do not require' adjustment after sharpening. 'I'he present invention has the advantage over the' intermittent indexing process that no periodic movement of withdrawal between the cutter and blank are required for indexing, the indexing mechanism itselfcan be eliminated, and, as above indicated, al1 of the'tooth spaces of the blank are operated on simultaneously.

In the drawing;V

. VFigurek 1 is a view illustrating diagrammatical- Y ly` the principal .constructional features of one possible'form of machine for cutting gears with a face-mill according to the present invention;

Figures 2, 3 and 4 are side elevational views illustrating .diagrammatically three successive stepsin'the' cutting 'of a gear with the face-mill;

and t Figures 5, 6 and'7 are end views of the cutter and blank, corresponding, respectively, to Figures 2, 3 and 4. y

I0. designates the cutting tool. This is provided with a plurality of circularly-arranged cutting blades II which,Y are identical with the blades of '4' a standard face mill gear cutter of `the intermittentA indexing typesuch'as shown, for instance,

Y in the patent maames E. Gieason No. 1,236,834

oflAu'gust 14, 1971.7. Instead of being arranged all'the way aroundrthe periphery of theV cutter. Y 40` head, asis the case inthe tool of the Gleason patent, the 4blades of the cutter I0 are arranged only `part way around the periphery of the cutter head. There is a relatively large blank space between `the last andiirst blades, I3 and I2, respecil; tively, of the cutter.

The blades between the blades I2 and, I3 are equally spaced from one another'and there is no restriction as to their number asllong as the necessary cutting clearance isl provided between successive blades. l 'I'he gear blank to be cut is designated at l5. In Figure 1 practicallyrall the teeth of the blank haveibeen cut, butV the other gures show the blank at the beginning of the cutting operation.

AUinthe cutting operation, the cutter and blank are brought into engagement and rotated continuously on their respective axes I6 and I1. Simultaneously there is a relative movement of to and fro translation produced between the cutter and the blank. This to and fro motion is timed to theV rotation of the cutter and, during cutting, to the rotation of the blank. For anyV theblank apex, that is, the translatoryxmovementV will-bean angular movement about the blank apex.V This is thecase shown in the drawing,

where the gear I being cut is a spiral bevel gearV and the axis I8 about which the translatory move- Y ment' takes place intersects Ythe axisA I1 of the blank in the' blank apex.

Figures 2 and 5 showthe cutter Il)y beginning to cut in the first tooth space 20 of the blank. The

iirst blade I2 of the cutter is Just taking its cut. The cutter is rotating in the direction indicated by the arrow 2|, while the blank is rotating in the direction indicated by the arrow 22. vThe cutter and blank continue to `rotate in these respective directionsthroughout the whole of the cutting operation. As the cutter rotates' on from the position shown in Figures Zand 5, movingthe blades, which follow the blade I2,v4 through the blank, the cutter is swung relative to the blank about the axis IIIl and in the direction indicated by the arrowV 23. lThe rate of the swinging moven ment, as the blades cross the blank, is equal toV the speed oi' rotation of the blank so that ras each blade of the cutter crosses the face of the blank the cutter and blank roll together. result is that there is a uniform cutting clear-v ance maintained during cutting between the blades and the side or sides of the'tooth or 'teeth being cut thereby. Whenv the last'blade l3` of the cutter has passedY through the tooth space 20 of the blank, as is shown in Figure 3, the cutterY will havebeen swung in its translatory movement about the axis Il through'an angle a.Y and the axis I6 of the cutter will have been carried'to the position 16'.) x V.

The blank-space of the cutter is now abreast of the gear blank, as clearly shown 'in Figures 3 and 6; The cutter and gear blank continue to rotate; in' the direction of the arrows 2l and` 22, vrespectively, but, as soon as Vthe last vblade I3'k of,

"15 The the cutter has cleared the `blank,"the translatory f motion is reversed and the cutter isfswung backv about the axis VIii to return it-to its initial posi-4 tion. The return translatory4 movement of the cutter is indicated by the arrow 24 in-Figure' 3.

' The continued rotation of the gear blank `dur'-v ing the time that the blank-space of thecutteris abreast of -it causes the gear blank to be indexed.I

Y'During the return swing of the cutter'aboutithe axis I8,'Hthejcutter will be ,carriedl back toits u initial position corresponding to that `of Figure4 2 and when the blade I2' again commencesto cut, the gear'blank will have rotated far enough, as

shown in'Flgures 4 and 7; so that the blade 'I2' will enter a new tooth space 25 of the gear blank.

At this moment, the swingingmovement of theY Y cutter will again be reversed so that as'the blades of the cutter once more pass across the blank,

the swinging movement will again be in the directionof the arrow 28.

From th precedingv description,` it will be seen',`

that there is a'complete oscillation ofthe cutter abouty the axis I8 for each revolution of the cutter I0 and that onv each revolution of the cutter, the

blades operate Sin a new tooth space ofthe blank.Vv

When'the blankhas made a complete' revolution, the cutter will have made a series of cuts on each tooth ofxtheblankY corresponding innumber to the number vof blades in the cutter.

the. blank, the tool win be red intoth blank so that on the next cut around, it will removeV further stock. The feed may be eifectedby a 65V v vAfter a cut around on all the toothspaces of y cutter rotations.

angle on the teeth ofthe blank. These adju'stef` ments have not been shown for'reasons of simplication. The cradle is mountedinva full-circular bearing in the frame 3| of the machine. g It is oscillated to impart the Arequired translatory movement to the cutter by reciprocation of a worm 32 which meshes with a wormwheel 33 that is secured to the cradle.

.The worm 32 is reciprocated bya cam 33. This produces an oscillatory motionof the cutter about the axis of the cradle corresponding to the translatory motion about the axis i8 .already described. The cam 33 will be driven in time with'the cutter rotation through any suitable mechanism, Vthe cam making one revolution for each revolution of the cutter shown. If the blades of the cutter are arranged in incre than one series, then a cam of the. type shown would be geared to the cutter to make a number of revolutions during each revolution of the cutter equal toI the number of series of blades in the cutter.`

The gear to be cutis secured to thework spindle 35 of the machine which is rotated by the worm wheel 3G and worm 3l in time with the cam and When the cam is so formed as to provide a quick-return motion of the cradle, the blades can be arranged around the greater portion of the periphery of the cutter, as shown. Were the cam made so that the return motion was at the 'same rate as the forward motion, the blades would have to be arranged only half way around the cutter and the remaining half of the cutter would tion isfintended to cover any adaptations, u'ses,

be blank.

If the tooth surfaces of the gear I5 lare to be generated, the generating motion can be produced by imparting preferably a step-bystep rotation to the worm 32. For this purpose, the shafti33, to which the worm is secured may be splined, as indicated at 39' and on the splined portionof the shaft there may be mounted a worm wheel Mi. This worm wheel may be rotated by a worm 4I and the worm may be rotated intermittently, that is, after each revolution of the blank, by any suitable mechanism. Rotation of the worm shaft 3B and worm 32 through the mechanism just described will impart a rotary movement to the Worm wheel 33 and cradle. 3i? which will combine with the oscillatory motion received from the cam 33 and will produce the generating action through the'timed rotation of the work. The spliningy of the shaft 38 permits of its rotation without interference with its reciprocation.

While the cradle Sii must swing back and forth' once for each revolution of the cutter if there are only one series of blades in the cutter and more often if there are a plurality of series of blades in the cutter, the amount of its' swing is much less than the amount of swing of the cradle in a machine operating according to the intermittent indexing process. In the intennittent indexing process, the cutter rotates a very .largelnumber of times in generating a tooth space, but the swing of the cradle during the cutter rotation is through an angle large enough to roll out the tooth f profile and usually is through several circular pitches of the blank. In the present invention, the cradle will be swung through less than one circular pitch. Therefore, while there are fewer blades in a cutter used in the present invention than in a cutter employed in an intermittent indexing operation, the cradle can be swung back and forth faster inV the present invention than in an intermittent indexing process and one factor compensates for the other so that the method of the4 present invention need not be slower than an intermittent indexing process.

By spacing the blades of the cutter far enough apart it wouldbe possible to swing the cradle back and forth ,betweentthe operation of successive blades or successive pairs of blades. ,Y Thus, successive bladesv or successive pars'of blades of the' cutter` could be made to enter successive tooth spaces of the blank as the cutter and blank rotate together. Going a step further, then, it will be seen that instead 'of using a rotating motiontocarry Ythe cutting bladesacross the face of a gear`r blank,- a reciprocating motion in a longitudinally curved path might be employed instead and a single tool used. In this case, the cradle would have a to and fro motion with each reciprocation of the: tool and the tool would cut on successive cutting strokes rin successive tooth slots of the lank. During the non-cutting or return strokes of the tool, the tool would be swung clear of the or embodiments of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the gear art and as may be applied to the essential features hereinbefore set forth and as fall within the scope of the invention or the limits of the appended claims.

Having thus claim is: l

l. The-,method of cutting longitudinally curved tooth gears which comprises rotating a face mill, which has a plurality of blades arranged part-way around its periphery only, inoperative relation with a continuously rotating gear blank, whilev producing aback and forth movement of translation between theA cutter and blank in time with the cutter rotation. Y 2. The. rmethod of cutting a longitudinali curved tooth gear which comprises employing a face mill, which lilas aplurality fof blades arranged around its periphery in one or more groups with `a. space between the last blade of one group and the rst blade of another, and `rotating said cutter continuously in 'engagement with aV continuously rotating gear blank while producing a back and forth movement of translation between the cutter and gear blank, said translatory move# ment being in timed relation with the gear blank rotation while a 'group of blades are passing through a tooth space of the gear blank, and operating to return the cutter to initial position while a. blank space of the cutter is abreast of the gear blank.

3. The method of cutting longitudinally curved tooth gears which comprises employing -a face4 mill, which has a plurality of blades arranged part-way around its periphery only, and rotating said cutter continuously in operative relation with a continuously rotating gear blank while prodescribed my invention, Vwhat Iv 204 blank, as in thefusual practice, and it would be ducing a back and forth movement of translation between the cutter and blank so timed that'durlng each revolution of -the cutter,Y one complete cycleof the translatory motion occurs.

4. The method of cuttinglongitudimally tlurvedY tooth gears which comprises-employing'a face mill, which has' a plurality of blades arranged Varound its vperipheryY in one or moreV groups with a blank Aspace' between the last and rst blad Vof the group or groups, and lrotating said cutter continuously in engagement with a continuously rotating gearvnblank while producing a'relative 'translatorymovement between the cutter and blank about an axis angularly disposed to the axis of the blank, said-trainslatory motion being timed to .the blank rotation while a.' group of blades of tliecutter are passing through a tooth space of the blank and acting to return the cutter to initial position while a blank 'space of they cutteris' abreast'of the gear blank.

5. In a machine for producing gears, a rotatable work support, a rotary face mill cutter, a carrier on which'one of said parts is mounted, said cutter having a plurality of blades arrangedrin one or more groups aro-und its periphery With a blank space between the last and i'rst blades of the group or groups, means for rotating the cutter fand work support continuouslyV on their respec- Y timed that during movement ofthe carrier inv one direction, a group of blades of the'cutteris pass-Y tive axes, and means for imparting a back and forth movement of translation to the carrier so ing through a tooth space Yof the gear blank and during movement of the carrier in the opposite direction, a blank space of the cutter is abreast of` the `gear blank. i

6. In a machine forproducing gears, a rotatable Work support, a rotary face mill' cutter, an oscillatory cradle upon which one of said parts is mounted,fsaid cutter having a plurality of Vblades arranged 'in one or more groups around its periphery with a blank space between the last and rst blades of the group or groups, means for roontheir respective axes, and-means for imparting an oscillatory movement to the cradle so timed that duringmovement ofthe cradle in one direc'- tion,l a` group of blades of the :cutter is passingl through a tooth space of the' blank, and during movement of the cradle in theopposite direction, alblank space of the cutter is abreast Vof* the gear blank,

7A The method of producing a. longitudinallyA curved tooth gear-which comprises actuatingV a Vcutting tool to move' the tool in a longitudinally curved path across the face of a continuously'rotating gear blank and then return Ythe toolt0 cutting position, and simultaneouslyimparting a. back and forthmovement of'I translation be#r tween the tool and blank, the'forward motion of translation being atzthesame rate asthe'blank rotation during cutting, and the-return motion taking place while the Atool is clear of the blank,

i so that, byY reason ofv the continuous rotation Y.fa,oolfi,'nso

of the blank; the tool willenter a different-tooth 1 space oi' the blankeach time it cuts;

8. In a machine for producing longitin'iinxl-illyrv curved 'toothgeara a work support, a ia'ce mill cutter having4r a plurality o! arcuately arranged blades extending part-way around its peripheryv` only with a gap betweenthe last andthe rst' blades which is ofngreater angular extent than thedistanoe between successive blades, means'for rotating the cutter, and means for producing a relative movement between the cutter and work support while the gap in the cutter is abreast of theM work to cause the blades of the cutter to` enter a different tooth space of the blank on each 'U revolution of the cutter.

9.' The method cfcutting longitudinally curvedv toothV gears which comprises rotating a facev mill gear cutter, which has a plurality of arcuately arranged bladesiextending part-way around its periphery only so that thereis a gap between the successive blades, in operative relation with a gear i blank and electng a relative movement between the cutter and blank while the gap in the cutter Vis abreast. of the blank to cause the blades of the cutter to entera different tooth space of the blank oneach revolution of the cutter. A

10. The method of producing a longitudinallyV curved tooth gear'which comprises actuating a cutting tool to"` move it in a longitudinally curved Y 20.1` last and first blades of the cutter which' is of i `greater angular extent than the distance between path ,acrossVV the face ofia. continuously rotat-Ify ing gear blank and then return the tool vtoxcut- Ating position', and Vsimultaneously imparting ay relative 'oscillating movement to the vtool `and als'v Y,

blank about an axis angularly disposed to the axis of the blank; the forwardv motion ofv Voscillation being ltimed to the blank rotation duringk cut,-V ting and the return motion of oscillation takingY ,place while the tool is clear ofthe blank so that by reason of the continuous rotation of the blank,

the tool enters a diierent itooth space of the l blankeach time it cuts.

1l. The methodV of cutting a` longitudinally curved tooth gear which comprises vemploying a face-mill gear cutter having aplurality of blades arranged thereon in an arc concentric with the cutter axis with at least two successive blades spaced for successivel engagement'withV corre-A sponding side tooth surfaces of different teeth of a blank. each'of said blades being so relieved that all points in a top cutting edge ofthe blade are at the same radial distance from the axis of the cutter,V and rotating said kcutter continuously vin one direction in .operative relation with a gear blank while'rotating the blankcontinuously in one direction and simultaneously producing a relative to and fro motion of translation between' the Vcutter and blank which is timed tothe blank Y rotationV during passage of blades across the face ofthe blank and in whichthe return motion occur's'while `thle space between blades, which are. arranged toengage successive teeth, is abreast of the blank.

B( E. sHLEsINGER; Y 

